Rfid-based moisture-sensing and leak-detection for building structures and methods of use

ABSTRACT

The inventive disclosures pertain to an improved moisture-sensing insulation panel for use in building structures that features enhanced leak-detection and analytical capabilities. The improved system features RFID-enabled moisture-sensing elements contained in a moisture-sensing membrane, and can measure impedance changes across the moisture-sensing membrane. In some variations, the system is designed to detect and measure moisture leakage and structural loading by way of biplanar capacitance measurements. RFID tags for moisture sensors are read by drones or robots and wirelessly transmitted to the Cloud/Internet for remote data analytics.

CROSS-REFERENCE TO RELATED APPLICATIONS

This patent application claims the priority benefit of U.S. PatentApplication No. 63/000,606, filed on Mar. 27, 2020, for “RFID-BasedMoisture-Sensing and Leak Detection for Building Structures and Methodsof Use.” In addition, this patent application hereby incorporates byreference U.S. Patent Application No. 63/000,606. For claim-constructionpurposes, if there are any irreconcilable differences between thedisclosures in the present patent application and U.S. PatentApplication No. 63/000,606, then the disclosures of the present patentapplication shall govern.

BACKGROUND

The mechanical integrity of a building structure can be severelycompromised by water infiltration, and the health of building occupantsmay be negatively impacted by the long-term persistence of moisturewithin occupied spaces due to the accumulation of mold, mildew, etc.Passive methods of leakage and moisture protection inherently carry riskbecause any evidence of dampness or wetness within a building structurealmost always is detected only after the damage has already been done.

Exterior insulation and finish systems (EIFS) are a general class ofnon-load-bearing building-cladding systems that provides exterior wallswith an insulated, water-resistant, finished surface in an integratedcomposite material system. EIFS first gained use in North America duringthe 1960s and grew in popularity because of the energy crisis of the1970s, but water-infiltration problems in early EIFS resulted in costlylitigation. This led to the development of drainable EIFS with adrainage plane located behind the insulation layer to prevent thebuild-up of excessive moisture within the system. Drainable EIFS issuperior to traditional stucco and face-sealed EIFS in terms ofmitigating the moisture that infiltrates the exterior cladding of abuilding.

FIG. 1A depicts an isometric rendering of a typical current-art EIFSinstallation (adapted from a drawing available onhttps://www.brickface.com/opt-eifs-siding/) as viewed from the exteriorside, where the underlying wall is represented by wooden framing membersand gypsum panel; however, the framing may be steel or other structuralmaterial and the paneling may instead be a poured-concrete or preformedmasonry wall (i.e., cinder blocks and mortar). The moisture-barriermembrane in such current-art systems may be both waterproof andvapor-permeable, or may be waterproof and non-vapor permeable, dependingon the climate where the structure is located. In commercial EIFS, themembrane is typically fluid-applied. Examples of some of the systemsavailable on the market include DriVit Backstop®NT™ and BASFSenershield-VB®. At the lower edge of the panel in a typical commercialexterior insulation & finish system (EFIS) is flashing and a drainagetrack to carry away excess water. The basecoat strips are applied overthe barrier membrane with a notched trowel, and this serves as anadhesive onto which the expanded polystyrene (EPS) or extrudedpolystyrene (XPS) insulating panel is installed. The notched trowelforms drainage channels in the basecoat, creating a drainage planethrough which excess water can flow by gravity so that moisture does notbuild up within the EIFS installation. Alternately, to create thedrainage plane, the facing surface of the EPS or XPS insulating panelsmay have vertically-oriented channels pre-cut into the foam material,which is a feature normally provided by the foam-panel manufacturers.The basecoat is coated over a strengthening mesh, and, in turn, this iscovered with the final finishing coat to create a relativelylightweight, yet strong, exterior finish for the building. The installedconfiguration of EIFS depends on the construction specifications as wellas the manufacturer and system that is used.

Excess moisture build-up within the EIFS system can lead to theformation of mold and fungus that could result in a so-called ‘sickbuilding’ creating a health hazard to the occupants. Drainable EIFSsolves the moisture-retention issues when the manufacturer'sinstallation instructions and guidelines are followed, but theeffectiveness of the drainage plane is still largely dependent upon theskill and competence of the installers, and if done improperly, the EIFSinstallation may be compromised. In the current art, as represented bycommercially-available EIFS systems, once installed, there is no way tocheck whether the EIFS drainage plane is functioning correctly. This isa glaring weakness in current-art EIFS systems.

Moisture may build-up within the cladding and structure materials if thefunction of the EIFS drainage plane is compromised either by poorinstallation practices that clogs the drainage channels with excessiveadhesives, or by foreign material that clogs the drainage channels, orby excessive water infiltration through the EIFS cladding that can occurfrom poor workmanship and/or materials. This is especially true alongjoints formed by decks and roofing, and at fenestrations from windowsand doors. Since the introduction of drainable EIFS, the risk of acompromised installation has been shifted away from the manufacturer andtowards the installation contractors.

Installation contractors, the installation methods used by thoseinstallation contractors, and the materials used for EIFS are imperfect.Therefore, it must be assumed that water will enter every EIFSinstallation at some point:

-   -   It is impossible to install sealants perfectly 100% of the time        for all joints.    -   The use of an incorrect diameter of backer rod can cause        improper gapping.    -   Surface contamination cannot always be removed correctly,        leading to poor adhesion.    -   Over the passage of time, cracks may appear in the EIFS        installation from thermal and mechanical cycling of the        structure.    -   Water may enter the drainage plane at imperfections, such as        between the EIFS and lamina, at the window frames, through        balcony elements, at railings, at doors, at service        penetrations, and from the roofing system.

Excess moisture that builds-up within the cladding and the underlyingstructure may damage the underlying structure and cause materialdeterioration from mold, decay, loss of strength, dimensionalinstability and corrosion. Excessive moisture may lead to:

-   -   Mold growth on gypsum board and fiberglass cavity insulation        materials; and/or    -   A loss of cohesive strength in gypsum boards and oriented strand        board (OSB) sheathing; and/or    -   The corrosion of metal studs leading to a discoloration of        material surfaces; and/or    -   Dimensional instability from the loss of cohesive and adhesive        properties of sealant-lamina interfaces, leading to cracks,        gaps, and other openings.

Currently, there is no way to easily monitor the drainage plane of anEIFS installation without physically drilling into the cladding to makemeasurements using a hand-held moisture-measurement instrument. Theeffectiveness of this method is quite limited because it can onlyspot-check a few locations within an installation. Typically, this typeof measurement is made initially during the inspection of new EIFSinstallations, or forensically, after moisture damage to the structurehas already occurred. The reality of this limitation is reflected by theexistence of specific EIFS insurance (see “Why You Should Opt for EIFSSiding,” available at https://www.eima.com/eifs-insurance) that may bepurchased by EIFS contractors to cover the potential liability arisingfrom EIFS installations.

In U.S. Pat. No. 7,768,412 to Vokey, a moisture-monitoring system forbuildings is described that uses externally-switched moisture-detectingsensors, and a method for isolating the location of a leak andcalculating the severity of the water infiltration is also described.However, the Vokey system is discretely applied with a plurality ofindividual wiring connections to a building structure and is thereforenon-intrinsic to the building envelope, necessitating additional effortto install and verify the system's integrity. Furthermore, the Vokeysystem requires that an external computerized Supervisory Control andData Acquisition (SCADA) system be installed within the monitoredstructure to switch the sensors and determine the location and severityof any detected leakage.

What is needed is an improved EFIS that integrates a moisture-sensingdevice into the insulation panel and uses self-powered, passive wirelessRFID technology to read data that represents the state of moisturewithin the EIFS drainage plane.

BRIEF SUMMARY

The inventive disclosures contained herein are designed to addresslimitations associated with the buildup of excessive moisture within theEIFS drainage plane. Moisture-sensing elements are integrated directlyinto the proximal (inward-facing) surface of the insulation boardmaterial, and the electronic-nature of the detection technology mayallow the improved insulation panel to become ‘smart’ and respond to thepresence of water and/or moisture within the drainage plane of the EIFSinstallation.

In embodiments, the configuration of the improved EFIS installationexists as a stand-alone intrinsic moisture-sensing panel, optimized toaccommodate the EIFS installation environment, requiring little to nodifferences in the installation protocols presently used by thecontracting construction trades. A method is also revealed for how thedata may be wirelessly and securely acquired from the EIFS insulatingpanel using passive RFID that requires no internal power source, andthen transmitted to a cloud-based application that may be used toperform predictive analytics. The improved moisture-sensing EIFS paneland data acquisition and processing method provides the followingadvantages:

-   -   Having an integrated sensing apparatus with the insulating panel        provides an EIFS installation with intrinsic moisture-monitoring        capability without the need for installing discrete sensors and        the associated externally-wired power and measurement        connections;    -   Exploiting the inherent capabilities of low-cost and        miniaturized RFID technology allows the EIFS insulation panel        itself to become a moisture-sensing device that functions as a        so-called edge device in the IoT (Internet of Things);    -   Moving the computational process to a cloud-based application        eliminates the need to install and connect a complex        computerized SCADA system within the monitored structures to        switch between sensors to read and process the data;    -   The RFID-based IoT edge-device for the cloud-based application        provides both the moisture-sensing and leakage-location method,        and allows trends to be exploited by predictive analytics that        can be used to bring a potentially compromised EIFS installation        to the attention of stakeholders;    -   Machine-learning AI (Artificial Intelligence) can be employed        within the cloud-based application to continuously improve        predictive performance by learning to recognize data patterns        that lead to trouble, and this predictive capability will        improve as the volume of data continues to grow across multiple        installations; and    -   The simplified and reduced-cost system provides building owners        with the benefits of a low-cost continuously or        semi-continuously monitored moisture-sensing system within the        exterior cladding of their building, and the peace-of-mind that        goes with it.

The moisture-sensing elements is an improvement over the configurationrevealed by U.S. Pat. No. 5,648,724 to Yankielun et al. (“Yankielun”)for “Metallic time-domain reflectometry roof moisture sensor,” whichprescribes that a transmission-line sensor be embedded within a mediumhaving a dielectric constant that changes in the presence of water.However, the moisture-sensing elements in the present inventivedisclosures have been adapted for integration within an insulation boardto provide an EIFS insulation panel with stand-alone intrinsic moisturesensing capability.

In an embodiment, the sensing device is a composite membrane in the formof a strip of metalized polymer material placed within a recessedchannel on the proximal surface of the insulation panel onto which amoisture-wicking layer has been placed, with another metalized polymerstrip placed over the proximal surface of the wicking layer, where thewicking layer between the metalized strips forms a dielectric. Theelectrical impedance between the two parallel metalized areas of thiscomposite membrane is then used to sense the presence of moisture bymeasuring the biplanar capacitance, the electrical resistance, or boththe biplanar capacitance and electrical resistance. The stack of layersare bonded together through friction-welding or by an adhesive process.

In another embodiment, the layer of wicking material is first placedwithin a recessed channel on the proximal surface of the insulationpanel, and a polymer layer that has two parallel metalized areas is thenplaced over the proximal surface of the first wicking layer, and overthe polymer layer with the two metalized areas, a second wicking layeris placed. The electrical impedance between the two parallel metalizedareas of this composite membrane is then used to sense the presence ofmoisture by measuring the coplanar capacitance, the electricalresistance, or both the coplanar capacitance and electrical resistance.

In other embodiments, there are additional strips of composite membranein an additional channel or channels with different geometricorientations placed on the proximal surface of the insulation panel. Instill another embodiment, the entire plane of the proximal surface ofthe insulating board is covered by a layer of the compositemoisture-sensing membrane.

In most applications, passive ultra-high frequency (UHF) Radio FrequencyIdentification (RFID) sensor tags are used to excite the capacitive orresistive sensing elements within the composite moisture-sensingmembrane to measure the presence of moisture.

In other embodiments, a plurality of discrete passive UHF RFID tagsbased on resistive/inductive/capacitive (RLC) impedance of the RFIDsensor antenna are integrated within the insulating panels. Tags basedon RLC impedance make use of specially-designed RFID sensor chips orsimply use standard retail RFID chips that are adapted to the dielectricconstant of the material that they are installed into. These RLCimpedance-based sensor tags do not require direct contact with water tosense the presence of moisture below the membrane. Because of thesensitivity of RLC impedance-based RFID sensor tags to the materialsthey are installed into, a baseline calibration is needed to calibratethe dry condition of the sensor tags.

In many embodiments, the discrete or panel-integrated RFID sensor tagsare used to provide data to determine whether moisture is present withinan EIFS drainage plane, and the unique digital code associated with eachRFID tag allows the panel where the moisture is detected to beidentified, thereby allowing the location of the moisture within an EIFSinstallation to be determined. This information is wirelesslytransferred to an RFID reader and from the reader, in some variations,the data is uploaded directly to a cloud-based application, while inother variations, the data is sent to the internet via a wireless routerand then on to the cloud-based application. The cloud-based applicationis capable of determining and displaying data trends, as well as toperform predictive-analytics using applied statistics andmachine-learning-based AI.

BRIEF DESCRIPTIONS OF THE DRAWINGS

FIG. 1A depicts an isometric-cutaway view of a current-art EIFSinstallation fragment.

FIG. 1B depicts an isometric-cutaway view of one embodiment of animproved EIFS installation fragment.

FIG. 1C depicts the FIG. 1B embodiment of an improved EIFS installationfragment that is opened to fully reveal the interior drainage-planemoisture-sensing apparatus.

FIG. 1D depicts another embodiment of an improved EIFS installationfragment that is opened to fully reveal the interior drainage-planemoisture-sensing apparatus.

FIG. 2A depicts one embodiment of an isometric-cutaway view of animproved moisture-sensing membrane configured to measure biplanarcapacitance.

FIG. 2B depicts a cross-sectional view of the FIG. 2A embodiment of theimproved moisture-sensing membrane.

FIG. 2C depicts an alternate embodiment of an isometric-cutaway view ofan improved moisture-sensing membrane configured to measure biplanarcapacitance.

FIG. 2D a cross-sectional view of the FIG. 2C alternate embodiment ofthe improved moisture-sensing membrane.

FIG. 3A depicts one embodiment of the proximal surface of an improvedEIFS panel.

FIG. 3B depicts an alternate embodiment of the proximal surface of animproved EIFS panel.

FIG. 3C depicts an embodiment of an improved EIFS panel's proximal ordistal surface, depending on whether it is part of a horizontal orvertical installation.

FIG. 3D depicts an alternate embodiment of an improved EIFS panel'sproximal or distal surface, depending on whether it is part of ahorizontal or vertical installation.

FIG. 3E depicts the distal surface of the FIG. 3A embodiment of animproved EIFS panel.

FIG. 4A depicts one embodiment of an electrical block-diagram of acomposite moisture-sensing membrane that uses biplanar capacitance.

FIG. 4B depicts an embodiment of an electrical block-diagram of acomposite moisture-sensing membrane that uses coplanar capacitanceand/or parallel resistance.

FIG. 4C depicts an embodiment of an electrical schematic diagram for abiplanar-capacitance measurement.

FIG. 4D depicts an embodiment of an electrical schematic diagram for acoplanar-capacitance and/or parallel-resistance measurement.

FIG. 4E depicts an electrical schematic diagram of a simple RC filter.

FIG. 4F depicts examples of electrical signals for several RCmeasurements.

FIG. 5 depicts an installation that employs several embodiments ofmethods of wireless readout and data delivery to a cloud-basedapplication.

FIG. 6A depicts one embodiment of a flow diagram of a method for mappingthe topography of a “smart” EIFS installation.

FIG. 6B depicts one embodiment of a flow diagram of a method forverifying a “smart” EIFS installation.

These drawings are intended to provide notional configurations and aretherefore not drawn to scale.

DETAILED DESCRIPTION I. Overview

The inventive disclosures contained herein are designed to address thelimitations of current-art EIFS installations, and primarily focus uponan improved insulation panel with an integrated moisture-sensingchannel, thereby providing state-of-the-art EIFS installations withintrinsic moisture-sensing capability for the drainage plane. Generally,one or more moisture-sensing elements are integrated directly into theproximal (inward-facing) surface of insulation-board material, and theelectronic-nature of the detection technology allows the improvedinsulation panel to become ‘smart’ and respond to the presence of waterand/or moisture within the drainage plane of the EIFS installation usingcapacitive and/or resistive sensing methods.

In one embodiment, the capacitive-sensing device is a composite membranein the form of a strip of metalized polymer material placed within arecessed channel on the proximal surface of an insulation panel ontowhich a hydrophilic moisture-wicking layer is placed, with anothermetalized polymer strip placed over the proximal surface of the wickinglayer, wherein the wicking layer between the metalized strips forms acapacitive dielectric. Because water has a much higher dielectricconstant than the wicking-layer material, when such moisture is presentwithin the insulation panel, the capacitance of the sensing device isincreased by an order-of-magnitude or more, enabling the detection ofthe moisture through electronic means. The change in biplanarcapacitance of this composite membrane can then be used to sense thepresence of moisture. Typically, the stack of layers is bonded togetherthrough friction-welding or by an adhesive process with low mobility ofthe adhesive into the wicking layer.

In another embodiment, the layer of wicking material is first placedwithin a recessed channel on the proximal surface of the insulationpanel, and a polymer layer that has two parallel metalized areas is thenplaced over the proximal surface of the first wicking layer, and overthe polymer layer with the two metalized areas, a second wicking layeris placed. The electrical impedance between the two parallel metalizedareas of this composite membrane can then be used to sense the presenceof moisture by measuring the change in coplanar capacitance, or thechange in electrical resistance, or both the change in coplanarcapacitance and the change in electrical resistance.

In other embodiments, there are additional strips of composite membranein an additional moisture-detection channel or channels with differentgeometric orientations that are placed on the proximal surface of theinsulation panel. The orientation of the moisture-detection channels isselected to take advantage of the downward movement of moisture bygravity within the EIFS drainage plane.

In yet another embodiment, the proximal surface of the improved panelhas pre-formed drainage channels and one or more moisture-detectionchannels with different geometric orientations that are placed on theproximal surface of this insulation panel. As before, the orientation ofthe moisture-detection channels is selected to take advantage of thedownward movement of moisture by gravity within the EIFS drainage plane.In variations, the entire plane of the proximal surface of theinsulating board is covered by a layer of the composite moisture-sensingmembrane.

In an embodiment, the base membrane of the composite moisture-sensingmembrane is formed from high-density polyethylene (HDPE) onto which ametalized layer formed by a vacuum metal deposition (VMD) process iscreated. The wicking layer can be comprised of a thin membrane ofpolypropylene/polyethylene (PP/PE), or of a layer of untreatedtightly-woven untreated nylon fabric, or of any other hydrophilic porousmembrane or moisture-wicking fabric material. In typical variations, themetalized layers over the wicking layer are formed through the VMDprocess of metal onto a thin carrier membrane that is made of a polymermaterial such as biaxially oriented polyethylene terephthalate (BoPET)film.

In other embodiments, the proximal surface of the compositemoisture-sensing membrane may be covered by a semi-permeable Nafion™perfluorosulfonic acid (PFSA) membrane that may allow the amount of basecoat material present in the EIFS drainage plane to be better detectedby the composite moisture-sensing membrane.

The stack of layers may be bonded together through a friction-weldingprocess or with an adhesive that exhibits low mobility into the wickinglayer during the curing process.

In other embodiments, a plurality of discrete passive ultra-highfrequency (UHF) RFID (Radio Frequency Identification) tags based onresistive/inductive/capacitive (RLC) impedance of the RFID-sensorantenna is integrated within the insulating panels. RFID tags based onRLC impedance make use of specially-designed RFID-sensor chips or simplyuse standard retail RFID chips that are adapted to the dielectricconstant of the material they are installed into. These RLCimpedance-based sensor tags do not require direct contact with water inorder to sense the presence of moisture below the membrane. Because ofthe sensitivity of RLC impedance-based RFID-sensor tags to the materialsthey are installed into, a baseline calibration is needed to calibratethe dry condition of the sensor tags.

Passive UHF RFID tags are used to excite the capacitive or resistivesensing elements within the composite moisture-sensing membrane tomeasure the presence of moisture. In some embodiments, since theinsulation panels are not restricted by area, the RFID dipole antennascan be made much larger than normally seen with UHF tags, therebyextending reading ranges.

The capacitance or resistive sensor integrated into the insulation panelare used to provide the RFID tag with data to determine whether moistureis present within an EIFS drainage plane, and the unique digital codeassociated with each RFID tag allows the panel in which the moisture isfound to be identified, thereby allowing the location of the moisturewithin an EIFS installation to be determined. This information can bewirelessly transferred to and from an RFID reader. In some embodiments,the data is uploaded directly to a cloud-based application, while inother embodiments, the data is sent to the Internet via a wirelessrouter and then on to the cloud-based application.

The initial installation of the improved moisture-sensing installationpanels within an EIFS installation typically requires that theinstallation topography (moisture-reading, RFID-tag ID, and physicallocation) to be mapped, and this is accomplished using an RFID reader inassociation with a surveyor-quality differential Global PositioningSystem (GPS) Global Navigation Satellite System (GNSS) device. In somevariations, the installation topography is mapped manually using ahand-held RFID reader and differential GPS device, while in othervariations, the installation topography is mapped using either a flyingdrone equipped with a high-resolution camera or video feed to carry theRFID reader. In all cases, at the time of installation, data related tothe installation (such as the GPS coordinates of the RFID tag, thestructure the tag is installed upon, and the identity of the installingcontractor) is written to the RFID tag's non-volatile memory andprotected by an encryption password using the RFID reader. Finally, thecloud-based application can display data trends and performingpredictive-analytics using applied statistics and machine-learning-basedArtificial Intelligence (AI).

II. Terminology

The terms and phrases as indicated in quotes (“ ”) in this Section areintended to have the meaning ascribed to them in this TerminologySection applied to them throughout this document, including the claims,unless clearly indicated otherwise in context. Further, as applicable,the stated definitions are to apply, regardless of the word or phrase'scase, to the singular and plural variations of the defined word orphrase.

The term “or”, as used in this specification, drawings, and any appendedclaims, is not meant to be exclusive; rather, the term is inclusive,meaning “either or both”.

References in the specification to “one embodiment”, “an embodiment”, “apreferred embodiment”, “an alternative embodiment”, “other embodiments”,“another embodiment”, “a variation”, “one variation”, and similarphrases mean that a particular feature, structure, or characteristicdescribed in connection with the embodiment is included in at least anembodiment of the invention. The appearances of the phrase “in oneembodiment”, “in one variation”, and/or similar phrases in variousplaces in the specification are not necessarily all meant to refer tothe same embodiment.

The term “couple” or “coupled”, as used in this specification, drawings,and any appended claims, refers to either an indirect or a directconnection between the identified elements, components, or objects.Often the manner of the coupling will be related specifically to themanner in which the two coupled elements interact.

The term “removable”, “removably coupled”, “readily removable”, “readilydetachable”, “detachably coupled”, and similar terms, as used in thisspecification, drawings, and any appended claims, refer to structuresthat can be uncoupled from an adjoining structure with relative ease(i.e., non-destructively and without a complicated or time-consumingprocess) and that can also be readily reattached or coupled to thepreviously adjoining structure.

The terms “transverse” and “longitudinal” as used in this specification,drawings, and any appended claims, respectively refer to the short orwidthwise dimension of a membrane, and the long or lengthwise dimensionof a membrane. The transverse direction (TD), when used with a membraneor panel, refers to the direction across the short dimension. Thelongitudinal direction (LD), when used with a membrane or panel, refersto the direction along the long dimension. The LD also refers to theso-called “machine” direction (MD), which is the direction a roll isprocessed (unrolled and/or rolled) during the manufacturing process.

As used in this specification, drawings, and any appended claims,directional and/or relational terms such as, but not limited to, left,right, nadir, apex, top, bottom, vertical, horizontal, back, front,lateral, proximal, and distal are relative to each other, are dependenton the specific orientation of an applicable element or article, areused accordingly to aid in the description of the various embodiments,and are not necessarily intended to be construed as limiting in thisspecification, drawings, and any appended claims.

Similarly, as used in this specification, drawings, and any appendedclaims, the terms “over” and “under”, are relative terms. For example,the improved moisture-sensing membrane strip is positioned “over” theproximal surface side of the insulation panel because the proximalsurface side is designated as the surface nearest to the structuralsubstrate.

The terms “discrete” and “integrated” are used to associate therelationship of the moisture-sensing elements with their installationpanels. “Discrete” implies that the sensing elements act as stand-alonesensors within a panel installation, while “integrated” implies that thesensing elements are part of the installation panel and therefore act inconjunction with the installation panel.

As applicable, the terms “about” or “generally” or “approximately”, asused herein unless otherwise indicated, means a margin of +/−20%. Also,as applicable, the term “substantially” as used herein unless otherwiseindicated means a margin of +/−10%. The terms “nominal” and “nominally”are used to indicate dimensions within a margin of +/−5%. The terms“reference” or “reference value” refer to non-critical dimensions orcharacteristics. The terms “typical” or “typically” refer to methods,compositions, or dimensions used in current-art and/or commerciallyavailable applications (including when current-art and/or commerciallyavailable applications are incorporated in the improved applicationsdescribed herein). It is to be appreciated that not all uses of theabove terms are quantifiable such that the referenced ranges can beapplied.

III. An Improved EFIS with Intrinsic Moisture-Sensing Capabilities

This Section III is directed to an improved EFIS with intrinsicmoisture-sensing capabilities for use in building structures, such asvertical wall cladding structures that are disposed above ground. Referto FIGS. 1B though 6B.

Mechanical Configuration of the Improved Moisture-Sensing EFIS Panel

Refer to FIGS. 1B, 1C, and 1D. FIG. 1B depicts an isometric-cutaway viewof one embodiment of the improved moisture-sensing insulation panel 1 aspart of an EIFS installation as viewed from the exterior side, whereinthe underlying wall is represented by wooden framing members 7 andgypsum panel 6; however, in variations the framing 7 can also be steelor other structural material and the paneling 6 can instead be apoured-concrete or preformed-masonry wall (i.e., cinder blocks andmortar). The moisture-barrier membrane 4 can be both waterproof andvapor-permeable, or both waterproof and non-vapor-permeable, dependingon the climate where the structure is located. In commercial EIFS, themembrane 4 is typically fluid-applied. At the lower edge of thestructural panel 6 is flashing 12 and a drainage track 11 to facilitatethe drainage of excess water. The basecoat strips 5 are applied over thebarrier membrane 4 with a notched trowel and this serves as an adhesiveonto which the expanded polystyrene (EPS) or extruded polystyrene (XPS)improved insulating panel 1 is installed. The improved insulating panel1 is depicted as a partially removed fragment to more clearly show thedrainage plane formed between the distal surface of barrier membrane 4and the proximal surface of the improved insulating panel 1. The notchedtrowel forms drainage channels in the basecoat, creating a drainageplane through which excess water may flow by gravity so that moisturedoes not build up within the EIFS installation.

Over the distal surface of the installed improved insulating panel 1,basecoat 9 is coated over a strengthening mesh 8, and this is in turncovered with the final finishing coat 10 to create a relativelylightweight-yet-strong exterior finish for the building. The basecoat 9,strengthening mesh 8, and final finishing coat 10 are depicted partiallyremoved to reveal keep-away-zones 3 that, in variations, are stenciledinto the distal surface of improved insulating panel 1 that indicatewhere the moisture-sensing channels 2 are located on the proximal sideof improved insulating panel 1. Keep-away-zones 3 provide indications toinstalling contractors where mechanical fasteners should not be driventhrough improved insulating panel 1 in order to avoid damaging themoisture-sensing-channel 2 elements.

The embodiment of the improved moisture-sensing insulation panel 1depicted in FIG. 1B is isometrically depicted in FIG. 1C as rotated away(A) from the underlying wall 6 and framing members 7 to reveal theproximal surface of the improved moisture-sensing insulation panel 1that normally faces the EIFS drainage plane. Moisture-sensing channels 2are typically, nut no necessarily, arranged in an X-pattern extendingbetween the corners on the proximal surface of improved insulation panel1. Improved insulating panel 1 has thickness t_(A). Thickness t_(A) canvary depending on the space restrictions of the installation and theinsulating R-value desired and can range between one and 13 inches. Asan example, the R-value of 1-inch-thick EPS is 3.85.

Another embodiment of the improved moisture-sensing insulation panel 1Ais isometrically depicted in FIG. 1D as part of an EIFS installation asdepicted in FIGS. 1B and 1C as rotated away (B) from the underlying wall6 and framing members 7 to reveal the proximal surface of the improvedmoisture-sensing insulation panel 1A that normally faces the EIFSdrainage plane. However, improved moisture-sensing insulation panel 1Ahas pre-formed or pre-cut vertical drainage channels 13 on the proximalsurface 14 of improved moisture-sensing insulation panel 1A. Thepre-formed or pre-cut vertical drainage channels 13 are depictednotionally, and is should be understood that any number and manyconfigurations of pre-formed or pre-cut vertical drainage channels 13are possible. As before, moisture-sensing channels 2 are typically, butnot necessarily, arranged in an X-pattern extending between the cornerson the proximal surface of improved insulation panel 1A, and it isexpected that the moisture-sensing channels intersect some or allpre-formed or pre-cut vertical drainage channels 13.

Mechanical Configurations of the EIFS Panel Composite Moisture-SensingMembrane

Refer now to FIGS. 2A through 2D for details of the compositemoisture-sensing membranes, as well as FIGS. 3A through 3E forembodiments of the composite moisture-sensing membranes within improvedmoisture-sensing insulation panel 1. (It should be noted note that onlyimproved panel 1 is depicted for clarity, but these various embodimentscan also apply to improved moisture-sensing insulation panel 1A.

FIG. 2A depicts an isometric view of the detail of a sectionmoisture-sensing channel 2 with width d1 and depth t_(B) that resides onthe proximal surface of improved moisture-sensing insulation panel 1 or1A. A base membrane 16 with thickness t_(C) can be composed ofhigh-density polyethylene (HDPE). Typically, width d1 is approximately 1to 2 inches and depth t_(B) is approximately 25 to 50 mils; however,these dimensions can vary depending on the application and configurationof moisture-sensing channel 2. A metalized coating 17 on the proximalsurface of base membrane 16 is created using a VMD process. Thepreferred specification for the metalized coating 17 is >99.9% purealuminum with an optical depth of >125 Angstroms, although other metalsand optical depths can be used. Additionally, metalized coating 17 canbe created by a sputter-deposition process (often performed with indiumtin-oxide, but other metals could be used). In other embodiments,metalized layer 17 is directly applied to the floor of moisture-sensingchannel 2 material using VMD, allowing the base membrane 16 to beeliminated. In all cases, the metalized coating 17 should exhibit asurface resistivity <10 ohms/square when measured in accordance withASTM D257.

Wicking layer 18 of thickness t_(D) can be formed from a hydrophiliclayer of PE/PP with a thickness t_(D) of approximately 10 to 20 mils;however, this dimension can vary depending on the application andconfiguration of moisture-sensing channel 2. Alternatively, wickinglayer 18 can be composed of untreated (i.e., there are nowater-repellant chemical additives) nylon 70-denier fabric with ataffeta weave, or other finely woven pattern, with a thickness t_(D) ofapproximately 13 mils. The untreated nylon exhibits hydrophilic wickingbehavior with moisture. Notably, untreated nylon fabric is often used asa liner for sports equipment or clothing to wick perspiration away froman athlete's skin. It should be recognized for those skilled in the artthat the wicking layer 18 can be composed of any porous hydrophilicmaterial with appropriate dimensional, chemical, and thermal propertiesthat can facilitate its function as a dielectric material that varieswith water content and conforms to the intended environmental andinstallation applications. Wicking layer 18 is attached to the metalizedcoating 17 using any low volatile organic compound (VOC) adhesive withlow mobility into wicking layer 18 during the curing process. A sensingmembrane 19 of width x1 is attached to the proximal surface of wickinglayer 18 using any low VOC adhesive with low mobility into wicking layer18. Sensing membrane 19 has a sandwiched metalized layer 20 formed by aVMD with the same characteristics as metalized layer 17. The coveringlayers over sandwiched metalized layer 20 of sensing membrane 19 aretypically composed of BoPET film, where overall thickness t_(E) ofsensing membrane 19 may be approximately 8 mils or less. For capacitancemeasurements, the edges of the sandwiched metalized layer 20 must becompletely sealed by the covering layers of sensing membrane 19 so thatmetalized layer 20 may not electrically contact the water in the wickinglayer 18. Gaps of distance d2 are left between the outer edges ofsensing membrane 19 and the walls of moisture-sensing channel 2 to allowwater or moisture within the EIFS drainage plane to contact wickinglayer 18. Gap width d2 may be approximately 100 to 200 mils, dependingon the configuration of the moisture-sensing channel 2 and the sensingmembrane 19. The covering layers of sensing membrane 19 may be composedof any polymer or fluoropolymer material with mechanical and chemicalproperties conforming to the intended environmental and installationapplications. A covering layer of semi-permeable membrane 21 may beplaced over the proximal surface of the composite moisture-sensingmembrane (detection device) residing within moisture-sensing channel 2and may be composed of PFSA with thickness t_(F), where t_(F) may bevary between approximately 100 and 300 microns (about 4 to 12 mils). ThePFSA material of covering semi-permeable membrane 21 is also used asmembrane in proton exchange membrane (PEM) fuel cells, which allowswater and ions to pass but no other larger molecules, and therefore thisproperty of semi-permeability may be useful to help the detection devicewithin moisture-sensing channel 2 sense the presence of basecoatmaterial 5 in contact with the proximal surface covering semi-permeablemembrane 21. The amount of contacting basecoat material 5 may provide anindication about the quality of the drainage plane configuration,because excess basecoat material 5 may clog the EIFS drainage plane,while excessively sparse basecoat material 5 may result in poor adhesionwith the improved moisture-sensing insulating panel 1 or 1A. Typicaluptake of water through the PFSA layer is 38% and typically occurs overa 1-hour period as measured by ASTM D570. Temperature will affect theuptake rate, where the rate increases with increasing temperature.Uptake rate may be improved by introducing small perforations (aroundseveral microns in diameter) into the semi-permeable membrane 21, inwhich case, a conventional polymer membrane material such as BoPET maybe possible to use instead of PFSA. It must be noted that because theEIFS drainage plane (depending on climate and installation) mayexperience dramatic cyclic swings in moisture content; therefore, it iscritical that the moisture detecting element be resistant to ioniccontamination that can introduce electrically-conductive residues to themoisture-sensing element wicking layer 18, and thereby impart aresistance change to the sensing element, even after the moisture withinthe EIFS drainage plane subsides and becomes completely dry. Thesemi-permeable membrane covering layer 21 is intended to provide thisresistance to ionic contamination.

The composite moisture-sensing membrane that forms the detection devicewithin moisture-sensing channel 2 may therefore be composed of aplurality of adhesively-attached layers and materials as describedpreviously, with an overall thickness of t_(C)+t_(D)+t_(E)+t_(F) orapproximately 25 to 45 mils, depending on the configuration. Thestrength of the adhesive bonds between layers should be sufficient toallow the improved moisture-sensing insulating panels 1 or 1A to bestored, transported and moved into place on the jobsite duringinstallation. The bonding adhesives should be chemically compatible withthe materials of the various layers and should be capable ofwithstanding the environmental conditions of the EIFS installation(ambient temperature extremes and moisture). Alternatively, a mechanicalfriction-welding process may be used to bond the various layers togetherinstead of adhesive or may be used in combination with adhesives to bondthe various layers together. The bond strength of the various layers ofthe sensing device within moisture-sensing channel 2 should besufficient to allow the panel to be cut-to-size in the field duringinstallation without tearing or delaminating the various layers from theunderlying insulating materials. A removable paper or silicone releaseliner (not depicted) may be adhered to the proximal surface of theimproved moisture-sensing insulating panels 1 or 1A to serve asprotection for the detection device within the moisture-sensing channels2 until the release liner is removed prior to installation. It may alsobe beneficial to introduce a factory-applied mastic sealant to thelongitudinal edges of the sensing elements at location 16, or in thefield when cuts are made, to protect the sensing element longitudinalends from ionic contamination.

FIG. 2B depicts a cross-sectional view of the detail of a section ofmoisture-sensing channel 2 depicted in FIG. 2A along the longitudinaldirection in the area where an electronic device 22 external to thesensing device residing in moisture-sensing channel 2 may be placed.Here the electronic device takes the form of a wireless RFID tag 22 andis depicted installed within cavity 26 below moisture-sensing channel 2opposite to the drainage plane. Wireless RFID tag 22 may be electricallyconnected 25A to the sandwiched metalized layer 20 of sensing membrane19 and is also may be electrically connected 25B to metalized layer 17.A backing plug 23 composed of panel 1/1A insulating material may beinstalled into cavity 26 over wireless RFID tag 22 as a method forreducing the open volume above RFID tag 22 to minimize areas that maytrap moisture. A factory-applied mastic sealant may also be applied tofill any potential water-trapping cavities. Metalized coating 24 may beplace on the surface of backing plug 23 that faces wireless RFID tag 22as a method for increasing the reading range. Although not shown, achemically-compatible elastomeric adhesive potting compound may also beplaced over RFID tag 22 under backing plug 23 to further reduce openvolume and may serve as additional protection for RFID tag 22. Theantenna configuration of the wireless RFID tag 22 may be optimized toextend the reading range.

FIG. 2C depicts an isometric view of the detail of a sectionmoisture-sensing channel 2A with width d1 and depth t_(B) that resideson the proximal surface of improved moisture-sensing insulation panel 1or 1A. Width d1 may be approximately 1 to 2 inches and depth t_(B) maybe approximately 25 to 50 mils, but these dimensions may vary dependingon the application and configuration of moisture-sensing channel 2A. Aswith the FIG. 2A embodiment, wicking layer 18 of thickness t_(C) may beformed from a hydrophilic layer of PE/PP with a thickness t_(C) ofapproximately 10 to 20 mils but this dimension may vary depending on theapplication and configuration of moisture-sensing channel 2A, or wickinglayer 18 may be composed of untreated (i.e. there are no water-repellantchemical additives) nylon 70 denier fabric with a taffeta weave, orother finely woven pattern, and with a thickness t_(C) of approximately13 mils; the untreated nylon may exhibit hydrophilic wicking behaviorwith moisture. Two longitudinally parallel sensing membranes 19A and 19Bboth of width x2 separated by gap d3 may be bonded to the proximalsurface of wicking layer 18 using any low VOC adhesive with low mobilityinto wicking layer 18. Sensing membranes 19A and 19B may each have asandwiched metalized layer 20 formed by a VMD with the samecharacteristics as metalized layer 17 described in the FIG. 1Aembodiment. The covering layers over sandwiched metalized layer 20 ofsensing membranes 19A and 19B may be composed of BoPET film, whereoverall thickness t_(E) of sensing membranes 19A, 19B are approximately8 mils or less.

For capacitance measurements, the edges of the sandwiched metalizedlayer 20 must be completely sealed so that metalized layer 20 does notelectrically contact the water in the wicking layer 18, 18A. Forresistance measurements, the edges of the sandwiched metalized layer 20can be left partially exposed, or either one of the upper or lowercovering layers of sensing membranes 19A, 19B can be eliminated. Anotherwicking layer 18A, also of thickness t_(D), can be bonded over sensingmembranes 19A, 19B using any low-VOC adhesive with low mobility intowicking layer 18A. The covering layers of sensing membranes 19A, 19B arecomposed of any polymer or fluoropolymer material with mechanical andchemical properties conforming to the intended environmental andinstallation applications. Gaps of distance d2 are left between theouter edges of sensing membranes 19A, 19B and the walls ofmoisture-sensing channel 2A. Gap width d2 is approximately 100 to 200mils, depending on the configuration of the moisture-sensing channel 2Aand the sensing membrane 19, and separation gap d3 is 50 to 100 mils,depending on the electrical characteristics desired (i.e., lowering thedimension of gap d3 will increase coplanar capacitance, but if gap d3 istoo narrow, the resistance sensitivity might become too great to beeffective). As with the FIG. 2A embodiment, a covering layer ofsemi-permeable membrane 21 is placed over the proximal surface of thecomposite moisture-sensing membrane (detection device) residing withinmoisture-sensing channel 2A and is composed of PFSA with thicknesst_(F), where t_(F) can be vary between approximately 100 and 300 microns(about 4 to 12 mils). The covering semi-permeable membrane 21 is usefulto help the detection device within moisture-sensing channel 2A sensethe presence of basecoat material 5 in contact with the proximal surfacecovering semi-permeable membrane 21.

The amount of contacting basecoat material 5 provides an indicationabout the quality of the drainage plane configuration, because excessbasecoat material 5 can clog the EIFS drainage plane, while excessivelysparse basecoat material 5 can result in poor adhesion with the improvedmoisture-sensing insulating panel 1, 1A. Typical uptake of water throughthe PFSA layer is 38% and typically occurs over a one-hour period asmeasured by ASTM D570. Temperature affect the uptake rate, where therate increases with increasing temperature. Uptake rate can be improvedby introducing small perforations (around several microns in diameter)into the semi-permeable membrane 21, in which case a conventionalpolymer membrane material such as BoPET is possible to use instead ofPFSA. It must be noted that because the EIFS drainage plane (dependingon climate and installation) can experience dramatic cyclic swings inmoisture content, it is critical that the moisture-detecting element beresistant to ionic contamination that can introduceelectrically-conductive residues to the moisture-sensing element wickinglayers 18, 18A, and thereby impart a resistance change to the sensingelement, even after the moisture within the EIFS drainage plane subsidesand becomes completely dry. The semi-permeable membrane covering layer21 is intended to provide this resistance to ionic contamination.

The composite moisture-sensing membrane that forms the detection devicewithin moisture-sensing channel 2A can, therefore, be composed of aplurality of adhesively-attached layers and materials as describedpreviously, with an overall thickness of 2t_(D)+t_(E)+t_(F), orapproximately 30 to 50 mils, depending on the configuration. Thestrength of the adhesive bonds between layers should be sufficient toallow the improved moisture-sensing insulating panels 1, 1A to bestored, transported, and moved into place on the jobsite duringinstallation. The bonding adhesives should be chemically compatible withthe materials of the various layers and should be capable ofwithstanding the environmental conditions of the EIFS installation(ambient temperature extremes and moisture). Alternatively, a mechanicalfriction-welding process can be used to bond the various layers togetherinstead of adhesive or can be used in combination with adhesives to bondthe various layers together. The bond strength of the various layers ofthe sensing device within moisture-sensing channel 2A should besufficient to allow the panel to be cut-to-size in the field duringinstallation without tearing or delaminating the various layers from theunderlying insulating materials. A removable paper or silicone releaseliner (not depicted) is adhered to the proximal surface of the improvedmoisture-sensing insulating panels 1, 1A to serve as protection for thedetection device within the moisture-sensing channels 2A until therelease liner is removed prior to installation. It may also bebeneficial to introduce a factory-applied mastic sealant to thelongitudinal edges of the sensing elements, or to introduce a masticsealant in the field when cuts are made, in order to protect thesensing-element longitudinal ends from ionic contamination.

FIG. 2D depicts a cross-sectional view of the detail of a section ofmoisture-sensing channel 2A depicted in FIG. 2C along the longitudinaldirection in the area where an electronic device 22 external to thesensing device residing in moisture-sensing channel 2A can be placed.Here the electronic device takes the form of a wireless RFID tag 22 andis depicted installed within cavity 26 below moisture-sensing channel 2Aopposite to the drainage plane. Wireless RFID tag 22 is electricallyconnected 25A to the sandwiched metalized layer 20 of sensing membrane19A and is also electrically connected 25B to the sandwiched metalizedlayer 20 of sensing membrane 19B. A backing plug 23 composed of panel1/1A insulating material is installed into cavity 26 over wireless RFIDtag 22 as a method for reducing the open volume above RFID tag 22 inorder to minimize areas that might trap moisture. A factory-appliedmastic sealant is also applied to fill any potential water-trappingcavities. Although not shown, a chemically-compatible elastomericadhesive potting compound can also be placed over RFID tag 22 underbacking plug 23 to further reduce the open volume and serves asadditional protection for RFID tag 22. The metalized coating 24 isplaced on the surface of backing plug 23 that faces wireless RFID tag 22as a method for increasing the reading range. The antenna configurationof the wireless RFID tag 22 can be optimized to extend the readingrange.

The wireless RFID tags 22 depicted in the embodiments of FIGS. 2B and 2Dmay be electrically connected 25A, 25B using an electrically conductiveadhesive such as, for example, Permabond® 820, with an electricalconductivity of >1×10E7 (m/ohm), a dielectric strength of 25 kV/mm, anda service temperature range of −55° C. to +200° C. (−65° F. to +390°F.). Considerations for the environmental conditions that the wirelessRFID tags 22 could be subjected to in EIFS applications have been made.For example, the electronic chips within wireless RFID tags 22 can havean automotive-grade-temperature operating range between −40° C. and+125° C. (−40° F. and +257° F.) and can have a non-operating-temperaturerange between −65° C. and +150° C. (−85° F. and +302° F.). In somevariations, wireless RFID tags 22 are hermetically sealed within ahydrophobic polymer or fluoropolymer covering to ensure that the devicesmay operate for decades without degradation.

Any moisture present in the drainage plane contacts the detection devicewithin the moisture-sensing channels 2, 2A and is drawn into wickinglayer 18A and/or wicking layer 18 through gaps d2 and/or separation gapd3. The porous material of the wicking layers 18, 18A have a relativepermittivity (i.e., dielectric constant) of approximately 1.5 to 2.4 forpolymer materials (polyethylene 2.2 to 2.4; see, e.g.,http://www.clippercontrols.com/pages/Dielectric-Constant-Values.html#P)and approximately 3 to 5 for nylon (nylon 4.0 to 5.0, or nylon resin 3.0to 5.0; see, e.g.,http://www.clippercontrols.com/pages/Dielectric-Constant-Values.html#N),while water has a relative permittivity of 80.2 at 68° F. (20° C.);therefore, between the dry and wet states of wicking layers 18, 18A,both the biplanar capacitance between sandwiched metalized layer 20 ofsensing membrane 19 and metalized coating 17, and the coplanarcapacitance between adjacent sandwiched metalized layers 20 of sensingmembranes 19A, 19B, may change by a factor of 20 to 50 (greater than oneorder of magnitude), allowing an external electronic measurement deviceto readily detect the presence of any water absorbed into wicking layers18, 18A within the detection device residing in moisture-sensingchannels 2, 2A. Electrical resistance between sensing membranes 19A and19B configured for resistance measurements is altered by the presence ofwater within wicking layers 18, 18A. The advantage of a resistance-basedmeasurement is that a simpler electronic measurement method can beperformed by wireless RFID tag 22; however, but the disadvantage ofrelying one a resistance-based measurement is the need to eliminate thecovering semi-permeable membrane 21 in order to allowelectrically-conductive ionic compounds within the moisture to becarried into the wicking layers 18, 18A, which also serves to make theresistance measurement inoperative if these electrically-conductiveionic compounds remain as residue within wicking layers 18, 18A when themoisture evaporates. The resistance-based measurement can also beinsensitive to the presence of base coat 5 that can be in contact withthe sensing device within moisture-sensing channel 2A. It should benoted that capacitive-based measurements may not be sensitive toelectrically-conductive ionic compounds that remain as residue withinwicking layers 18, 18A.

FIG. 3A depicts a proximal surface view of the improved moisture-sensinginsulating panel 1 with moisture-sensing channel 2/2A with width d1arranged in an X-pattern, extending from corner to corner of theimproved moisture-sensing insulating panel 1, with panel dimensions ofw1 in width and w2 in height. A typical dimension can be w1=4 feet andw2=2 feet, and for purposes of the discussions remaining herein, thedimensions w1=4 feet and w2=2 feet shall be retained to provide areference for any further cited examples. However, it should beunderstood that there will be much variation in these dimensionsdepending on the EIFS installation configuration. The wireless RFID tag22 installation below moisture-sensing channel 2/2A as described forFIGS. 2B and 2D is depicted by the dashed rectangle in the center of thedrawings. The X-shaped moisture-sensing channel 2/2A arranged diagonallyis a preferred embodiment and can provide full horizontal coverage forwater draining downwards within the drainage plane under the force ofgravity, even with improved moisture-sensing insulating panel 1installed vertically and arranged with either with the w1 width or thew2 height aligned along the direction drainage, and even when the panel1 is altered by cutting during installation.

FIG. 3B depicts a proximal surface view of the improved moisture-sensinginsulating panel 1 with moisture-sensing channel 2/2A with width d1arranged in a diagonal-pattern, extending from the lower left corner tothe upper right corner of the improved moisture-sensing insulating panel1, with panel dimensions of w1 in width and w2 in height. The wirelessRFID tag 22 installation below moisture-sensing channel 2/2A asdescribed for FIGS. 2B and 2D is depicted by the dashed rectangle in themiddle of the drawing. The single moisture-sensing channel 2/2A arrangeddiagonally provides full horizontal coverage for water drainingdownwards within the drainage plane under the force of gravity, evenwith improved moisture-sensing insulating panel 1 installed verticallyand arranged with either with the w1 width or the w2 height alignedalong the direction drainage, and even when the panel 1 is altered bycutting during installation.

FIG. 3C depicts both a distal surface and a proximal surface view of theimproved moisture-sensing insulating panel 1 with moisture-sensingchannel 2/2A, with width d1 arranged along the longitudinal axis of theinsulating panel 1, extending from the left edge to the right edge ofthe insulating panel 1, and with panel dimensions of w1 in width and w2in height. For horizontal distal surface installations of the FIG. 3Cimproved moisture-sensing insulating panel 1, the sensing elementsreside on the insulating panel 1 surface facing away from the substrate,and the single moisture-sensing channel 2/2A arranged horizontally isaugmented by a plurality of small channels 36 cut into the surface ofthe insulating panel 1. The plurality of small channels 36 are intendedto facilitate the transport of water from the transverse edges ofinsulating panel 1 to the moisture-sensing channel 2/2A by means ofcapillary action. Additionally, wicking material 18 can be placed intoeach of the plurality of small channels 36 to facilitate the transportof water from the transverse edges of insulating panel 1 to themoisture-sensing channel 2/2A by means of wicking action, which enhanceswater transport at the cost on increasing the complexity of the improvedmoisture-sensing insulating panel 1. To eliminate RF interference fromthe electrically-conducting elements within the moisture-sensing channel2/2A, wireless RFID tag 22 is installed above the moisture-sensingchannel 2/2A in this configuration and is depicted as a dashedrectangle. This application can be installed under the horizontalwaterproofing membranes used for decking, balconies, and roofinginstallations. Furthermore, the distal surface configuration of the FIG.3C improved moisture-sensing insulating panel 1, when used undersingle-ply roofing, does not compromise the attachment strength offully-adhered (i.e., adhesively attached) membrane installations.

For vertical proximal surface EIFS installations of the FIG. 3C improvedmoisture-sensing insulating panel 1, the single moisture-sensing channelwith width d1 is arranged along the longitudinal axis of the insulatingpanel 1, extending from the left edge to the right edge of theinsulating panel 1, with panel dimensions of w1 in width and w2 inheight. This configuration is most effective at sensing water drainingdownwards within the drainage plane under the force of gravity when theimproved moisture-sensing insulating panel 1 is installed with the w1width or the w2 height aligned perpendicular to the direction drainage.The wireless RFID tag 22 installation below moisture-sensing channel2/2A as described for FIGS. 2B and 2D is depicted by the dashedrectangle at the center of the drawing.

FIG. 3D depicts both a distal surface and a proximal surface view of theimproved moisture-sensing insulating panel 1, with moisture-sensingplane 2C extending across the entire distal or proximal surface ofimproved moisture-sensing insulating panel 1, and with panel dimensionsof w1 in width and w2 in height. For horizontal distal surfaceinstallations of the FIG. 3D improved moisture-sensing insulating panel1, the moisture-sensing plane 2C resides on the insulating panel 1surface facing away from the substrate. A covering layer ofsemi-permeable membrane 21 (depicted as a fragment) is placed overmoisture-sensing plane 2C. To eliminate RF interference from theelectrically-conducting elements within the moisture-sensing channel2/2A, wireless RFID tag 22 is installed above the moisture-sensingchannel 2/2A in this configuration and is depicted as a dashed rectangleat the center of the drawing. This application can be installed underthe horizontal waterproofing membranes used for decking, balconies, androofing installations.

For vertical proximal surface EIFS installations of the FIG. 3D improvedmoisture-sensing insulating panel 1, the moisture-sensing plane 2Cextends across the entire proximal surface of improved moisture-sensinginsulating panel 1, with panel dimensions of w1 in width and w2 inheight. The wireless RFID tag 22 installation below moisture-sensingplane 2C is depicted by the dashed rectangle at the center of thedrawing. The single moisture-sensing plane 2C arranged horizontallyprovides high sensitivity for detecting any moisture within the EIFSdrainage plane adjacent to the moisture-sensing plane 2C.

FIG. 3E depicts a distal surface view of the FIG. 3A embodiment ofimproved moisture-sensing insulating panel 1. Keep-away zones 3 arestenciled onto the distal surface of improved moisture-sensinginsulating panel 1 to designate where contractors should not drivemechanical fasteners through the panel 1. The keep-away zones 3 havewidths D1′ that are approximately 20% greater than moisture-sensingchannel 2/2A to help ensure that fasteners are not inadvertently driventhrough the moisture-sensing channels 2/2A. A plurality of bar code 27patterns are ink-stamped or printed onto the distal surface of improvedmoisture-sensing insulating panel 1. The bar code 27 patterns representthe unique digital ID of the wireless RFID tag 22 installed into theassociated improved moisture-sensing insulating panel 1, which can implythat the ink-stamping or printing process is a factory operation. Theunique digital ID of the installed wireless RFID tag 22 is captured byan RFID reader during the assembly process and the corresponding barcode 27 patterns that encode the unique digital ID are then ink-stampedor printed onto the distal surface of improved moisture-sensinginsulating panel 1 as depicted. The unique digital ID of the installedwireless RFID tag 22 encoded as a visible bar code 27 facilitates theinstallation topography of the EIFS panels that can be recorded/mappedconcurrently during the installation process.

The factory-integrated nature of the improved moisture-sensinginsulating panels 1, 1A of various configurations are ideally suited forprefabricated EIFS panels, where the EFIS panels are custom-fabricatedfor an installation within a factory setting. These completed EFISpanels are then transported to the jobsite and installed, saving time,and reducing the installation variation and compromised quality thatoften arises during a direct installation by a contractor at a jobsite.A commercial example of a prefabricated EIFS panels is the DryvitTech21® prefabricated panel program (see, e.g.,http://www.dryvit.com/our-solutions/panelization/).

Electrical Configurations of the EIFS Panel Composite Moisture-SensingMembrane

Now refer to FIGS. 4A, 4B, 4C, 4D, and 4E. FIG. 4A depicts an electricalblock-diagram for the FIG. 2A embodiment of the compositemoisture-sensing membrane (detection device) residing withinmoisture-sensing channel 2. Dashed line 22 denotes the components withinthe wireless RFID tag 22. Sensing area 19/20 with width x1 is shownarranged along the longitudinal axis of the detection device residingwithin moisture-sensing channel 2. The sensing area 19/20 has acorresponding external capacitance-measurement device Va representingwireless RFID tag 22 and is connected via electrical interface wiring25A and 25B. The signal ground denotes the electrical node that iscommon to the external capacitance-measurement device Va to which allmeasurement currents return to the source. Biplanar capacitance existsbetween each sensing area 19/20 and the metalized coating 17 of basemembrane 16 across the thickness and across the opposite surfaces ofwicking layer 18.

FIG. 4B depicts an electrical block-diagram for the FIG. 2C embodimentof the composite moisture-sensing membrane (detection device) residingwithin moisture-sensing channel 2A. Dashed line 22 denotes thecomponents within the wireless RFID tag 22. Sensing areas 19A and 19B,each having width x2 and separated by distance d3, are shown arrangedalong the longitudinal axis of the detection device residing withinmoisture-sensing channel 2A. The sensing areas 19A and 19B have acorresponding external capacitance-measurement device Vb representingwireless RFID tag 22 and are connected via electrical interface wiring25A and 25B. The signal ground denotes the electrical node that iscommon to the external capacitance-measurement device Vb to which allmeasurement currents return to the source. Coplanar capacitance existsbetween sensing areas 19A and 19B across the coplanar distance d3 ofwicking layers 18 and 18A.

Biplanar capacitance yields a large change in capacitance when wickinglayer 18 absorbs moisture. Coplanar capacitance yields a smallermagnitude of capacitance, but still may experience a large relativechange in capacitance when wicking layers 18 and 18A absorb moisture.

FIG. 4C depicts an electrical schematic diagram of the FIG. 4A blockdiagram with biplanar capacitance C_(biplanar). Protection device TVSaprotects the wireless RFID tag 22 from electro-static discharges (ESD).Impedance Zatest represents a test load present within the wireless RFIDtag 22 that allows self-testing and diagnostic checks of the detectiondevice residing within moisture-sensing channel 2. Resistance Rarepresents a measurement load necessary to create the RC time constantsbetween Ra and C_(biplanar), while time-varying current i_(a)(t) flowsthrough Ra and C_(biplanar), and the time-varying voltage V_(a)(t)measurement determines if the capacitance value of C_(biplanar) haschanged. The values selected for Ra correspond to the expected levels ofC_(biplanar) capacitance and the expected change in capacitance betweenthe dry and wet conditions of wicking layer 18 of the detection deviceresiding within moisture-sensing channel 2, as described for FIG. 4E.Electrical-interface wiring 25A and 25B represent the connecting wiresto the detection device capacitance C_(biplanar). The signal grounddenotes the electrical node common to the external measurement devicesVa.

Biplanar capacitance C_(bp) in Farads is defined as shown in Equation[1] below:

$\begin{matrix}{C_{bp} = \frac{ɛ_{0}ɛ_{r}{wl}}{t}} & {{Equation}\mspace{14mu}\lbrack 1\rbrack}\end{matrix}$

Where:

-   -   x1=l;    -   w1′=w(diagonal length of panel 1); and    -   t_(D)=t(wicking layer 18 thickness)

TABLE 1 Biplanar Capacitance Values With Moisture-Sensing MembraneParameters Capacitance ×1 w_(1′) Increase dry (inches) (inches) t_(D)(mils) ε_(r) dry ε_(r) wet C_(bp) (Farads) dry C_(bp) (Farads) wet towet 1.8 54 10 2 60 4.37 × 10E−9 1.31 × 10E−7 ×30 1.8 54 20 2 60 2.18 ×10E−9 6.55 × 10E−8 ×30

For the calculations in Table 1, the percent fill of wicking layer 18was set to 25%, which yielded an ε_(r) wet value of 60 with ε_(r)water=80.2. The difference in biplanar capacitance is approximately 30times between a completely dry wicking layer 18 and a fully saturatedwet wicking layer 18. This large change in biplanar capacitance betweendry and wet conditions provides very good electrical-measurementsensitivity for detecting the presence of moisture in wicking layer 18.

FIG. 4D depicts an electrical schematic diagram of the FIG. 4B blockdiagram with coplanar capacitance C_(coplanar). Protection device TVSbprotects the wireless RFID tag 22 from electro-static discharges (ESD).Impedance Zbtest represents a test load present within the wireless RFIDtag 22 that allows the wireless RFID tag 22 to perform self-testing anddiagnostic checks of the detection device residing withinmoisture-sensing channel 2A. Resistance Rb represents a measurement loadnecessary to create the RC time constants between Rb and C_(coplanar),while time-varying current i_(b)(t) flows through Rb and C_(coplanar),and the time-varying voltage V_(b)(t) measurement determines if thecapacitance value of C_(coplanar) has changed. The values selected forRb correspond to the expected levels of C_(coplanar) capacitance and theexpected change in capacitance between the dry and wet conditions ofwicking layers 18 and 18A of the detection device residing withinmoisture-sensing channel 2A, as described for FIG. 2C.Electrical-interface wiring 25A and 25B represent the connecting wiresto the detection-device capacitance C_(coplanar). Resistance Rwaterrepresents the resistance within wicking layers 18 and 18A from water.The signal ground denotes the electrical node common to the externalmeasurement devices Vb.

Coplanar capacitance C_(ep) in Farads is defined as shown in Equation[2] (see also, Clayton R. Paul, “Analysis of Multiconductor TransmissionLines,” 2nd Ed., 2008):

$\begin{matrix}{{C_{cp}(s)} = \left\{ \begin{matrix}{{\frac{ɛ_{r}l\;{\ln\left( {{- \frac{2}{4\sqrt{\frac{d^{2}}{\left( {d + {2w}} \right)^{2}} - 1}}}\left( {{4\sqrt{1 - \frac{d^{2}}{\left( {d + {2w}} \right)^{2}}}} + 1} \right)} \right)}}{377\pi v_{o}},}\ } & {{{for}\mspace{20mu} 0} < \frac{d}{d + {2w}} \leq \frac{1}{\sqrt{2}}} \\{\frac{ɛ_{r}l}{120v_{o}\;{\ln\left( {{- \frac{2}{\sqrt{\frac{d}{d + {2w}} - 1}}}\left( {\sqrt{\frac{d}{d + {2w}}} + 1} \right)} \right)}}\ ,} & {{{for}\mspace{20mu}\frac{1}{\sqrt{2}}} < \frac{d}{d + {2w}} \leq 1}\end{matrix} \right.} & {{Equation}\mspace{14mu}\lbrack 2\rbrack}\end{matrix}$

Where:

-   -   permittivity ε=ε₀ε_(r);    -   permeability μ=μ₀;    -   d₃=d (separation between sensing elements 19A and 19B);    -   w1′=l (diagonal length of panel 1); and    -   x2=w. All distance dimensions are in meters.

TABLE 2 Coplanar Capacitance Values With Moisture-Sensing MembraneParameters Capacitance ×2 w1′ d₃ increase dry (inches) (inches) (inches)ε_(r) dry ε_(r) wet C_(bp) (Farads) dry C_(bp) (Farads) wet to wet 0.954 0.05 2 60 7.72 × 10E−11 2.32 × 10E−9 ×30 0.9 54 0.10 2 60 6.69 ×10E−11 2.01 × 10E−9 ×30

For the calculations in Table 2, the percent fill of wicking layers 18and 18A was set to 25%, which yielded an ε_(r) wet value of 60 withε_(r) water=80.2. A symmetrical wicking layer above and below sensingareas 19A and 19B was assumed. The difference in coplanar capacitance isapproximately 30 times between completely dry wicking layers 18 and 18Aand fully saturated wet wicking layers 18 and 18A. Although the coplanarcapacitance levels are around two orders-of-magnitude less than theequivalent biplanar capacitance values shown in Table 1, the largechange in coplanar capacitance between dry and wet conditions stillprovides very good electrical-measurement sensitivity for detecting thepresence of moisture in wicking layers 18 and 18A.

FIG. 4E depicts the schematic for a generic low-pass RC filter, whereVdrive represents a drive voltage from a wireless RFID tag (variousembodiments), R represents resistance, C represents capacitance, andVcap represents the measurement of the voltage applied by Vdrive throughresistance R across capacitance C. The dashed boundary Panel representswhat is contained within the detection device residing withinmoisture-sensing channels 2 and 2A. The Signal Ground represents thecommon voltage node where the electrical current from Vdrive returns.Resistance R may be a fixed value (resistors Ra or Rb, as shown in FIGS.4C and 4D) within wireless RFID tag 22, while capacitance C may be thebiplanar or coplanar capacitance within the detection device residingwithin moisture-sensing channel 2 and 2A (see FIGS. 4C and 4D) that canvary with moisture content, as described in Tables 1 and 2. Theelectrical RC time constant τ is altered by changes to the capacitancevalue C within the detection device residing within moisture-sensingchannel 2 and 2A.

Capacitator voltage Vcap while charging and discharging is defined asshown in Equation [3] below:

$\begin{matrix}{{V_{cap}(t)} = \left\{ \begin{matrix}{{{Charging},}\ } & {V_{drive}\left( {1 - e^{{- t}/_{\tau}}} \right)} \\{{{Discharging},}\ } & {V_{drive}\left( e^{{- t}/_{\tau}} \right)}\end{matrix} \right.} & {{Equation}\mspace{14mu}\lbrack 3\rbrack}\end{matrix}$

-   -   Where: τ=RC

FIG. 4F depicts the waveforms at Vcap in volts for various states ofwicking layer 18, 18A in the detection devices residing withinmoisture-sensing channels 2, 2A, where capacitance change occurs whenwicking layer 18, 18A absorbs moisture, which results in a change in thebiplanar capacitance between the sensing areas 19/20 and the metalizedcoating 17 or results in changes in the coplanar capacitance betweenadjacent sensing areas 19A and 19B. A square wave is applied by Vdrivebetween 0V and 3V, with period=t3−t1, V_(drive_high)=t2−t1, andV_(drive_low)=t3−t2. The square-wave period and R are set be selected toproduce the maximum difference in average voltage between the DRY andWET conditions of wicking layer 18/18A, as represented by Vaverage3 andVaverage1, respectively, as determined by the range of RC timeconstants, where C represents the improved moisture-sensing membranecapacitance as determined by the difference between τ₃ and τ₁, againrespectively.

IV. An Improved Method of Building-Structure Installation andLeak-Detection

This Section IV is directed to an improved method of installing animproved moisture-sensing insulation panel for use in a buildingstructure, and an improved method of detecting and locatingpost-installation leaks in the building structure. Refer to FIGS. 1Bthough 6B.

Installations and Methods of Use of the Improved Moisture-Sensing EIFSPanel

Referring to FIG. 5, which depicts an installation with severalembodiments of methods of wireless readout and data delivery to thecloud-application, the two improved moisture-sensing panels 1 areintended to represent a notional installation process of an EIFS wallcladding. The location of wireless RFID tags 22 within the improvedmoisture-sensing panels 1 are denoted by the dashed quadrangles 22.

Typically, the wireless and passive RFID tags 22 use transceivercomponents that do not require an internal power supply such as abattery and are instead powered from the energy of the reading signal.The RFID tags 22 allows user data to be both read and written to amemory location within each RFID tag 22. In variations, the RFID tag 22has the capability to encrypt the information stored within its memorylocations to prevent the unauthorized deletion, overwriting, or anyother malicious or unintentional modification of the RFID tag 22 dataand information. Additionally, blockchain cryptographic hash can beused, which ensures that the collection, storage, and readout of thedata is secure by design, thereby enabling trust that the data has notbeen tampered with.

In most embodiments, the RFID tag 22 has the capability to be readpassively from a distance greater than 10 feet. In one embodiment, theRFID tag 22 is an Electronic Product Code (EPC) Class 3 Gen 2 Version 2ISO 18000-6C-Compliant RFID tag and is be Pb-Free, Halogen Free/BFRFree, and RoHS-compliant for environmental responsibility. EPC tagsoperate in the ISM (Industrial Scientific and Medical) UHF 902-928 MHzband for passive remote sensing and require no installed batteries orpower sources, and instead scavenge power only from the radio-frequency(RF) energy of the reading devices and then communicate back to thereader during this time using backscatter. An EPC Class 3 tag hasread-write capability with onboard sensors capable of recording externalparameters. An EPC Generation 2 tag has four banks of non-volatilememory (Reserved Memory, EPC Memory, Tag Identification—or TID Memory,and User Memory). Finally, Version 2 of the EPC Gen 2 standard includesbuilt-in 128-bit data encryption that allows a proprietary readingprotocol to be established (i.e., the tags described herein can onlycommunicate with RFID readers that are equipped with the properdecryption protocols).

In most embodiments, the RFID tags 22 Class 3 sensory capabilityincludes temperature and several additional sensor interfaces that canbe configured for the sensory application, such as measuringcapacitance, currents, or voltage levels. An example of an EPC Class 3sensory tag chip that can be used is the AMS SL900A, with an on-board±0.5° C. temperature measurement sensor that can read across a −40° C.to +125° C. range, and with interfaces for up to two additional sensorsexternal to the chip. The SL900A chip includes a driver voltage andreferences capacitor location to measure capacitive-based sensors. Thereference capacitor used for the SL900A chip would take the place of theload resistors Ra and Rb depicted in FIGS. 4C and 4D. For high-rateproduction, a custom-designed Application-Specific Integrated Circuit(ASIC) may be more cost effective, because the ASIC EPC sensory-tag chipmay be optimized for a specific application, with only the circuitryrequired to perform the functions needed.

Generic longevity specifications for Gen-2 chips are 40 to 50 years ofdata retention and 100,000 write cycles. Gen-2 tags can have a readrange of over 16 meters or 52 feet when using the full 4-Watt EffectiveIsotropic Radiated Power (EIRP) legally allowed on the readers by theFCC and other global regulators. Range can be effectively extended forUHF Gen-2 tags by increasing the size of the dipole antenna array.Typically, to save space, Gen-2 tags are restricted to a size thatapproximates a credit card, or approximately 4 inches in length, whichequates to a ¼-wavelength dipole antenna. The wavelength of a 1 GHzsignal is approximately 12 inches. It should be noted that 1 GHz is nearthe UHF 902-928 MHz band or the 0.902-0.928 GHz wavelength. Because thesize restriction might not be as important for EIFS applications, thewireless RFID tags 22 can have full-wavelength dipole antennas, and fourtimes (or more) the effective antenna array area over ¼-wavelengthdipole antennas. This theoretically doubles the reading range to around100 feet, because the RFID readers 29, 32, and 33 act as point sources,where the reader's radiated power decreases as an inverse-square of thedistance between the reader and the tag. Reading range can also beincreased by placing a reflective-metalized-conductive layer immediatelyunder the installed wireless RFID tags 22, as described for metalizedcoating 24 in FIGS. 2B and 2C, and this reflective-metalized-conductivelayer function can also be served by metalized coatings 17, 20 presentwithin the detection devices residing within moisture-sensing channels2, 2A.

The actual reading distances may be dependent upon insulation panel 1thicknesses and cladding materials 8, 9, and 10; the reading angles; andthe presence of any line-of-site obstructions, including water, snow,and ice. Furthermore, there is an upper limit to how large a wirelessRFID tag 22 antenna can become due to parasitic-impedance losses fromstray capacitance and inductance that can negatively impact the abilityof the RFID chip to drive the antenna signal. Therefore, each EIFSinstallation requires a different approach to obtain complete readingcoverage across the entire area of the building structure.

FIG. 5 also depicts several embodiments of methods to extractmoisture-sensing data from the EIFS installation through wireless RFIDtags 22. A flying remotely-controlled drone 28 carries RFID reader 29and a high-definition camera or video-recording device 30. Drone 28 RFIDreader 29 is used to read 29B wireless RFID tag 22 in order to obtainboth the tag digital identification (ID) number and tag data that caninclude moisture content and temperature measurements. The distance fortaking readings 29B is dictated by the power of the RFID reader 29,which can be limited below full EIRP due to the limited battery power indrone 28. The limited reading range may not present a problem for drone28 based wireless RFID tag 22 readings because the drone 28 can fly toany area of the installation. A drone 28 based wireless RFID tag 22reading method 29B is considered to be semi-continuous monitoring, withthe frequency of monitoring set by the time interval between drone 28based surveys.

In variations, a handheld RFID reader 32 that also has a differentialGPS device 31 can be used to obtain wireless RFID tag 22 information, asdescribed above, for the drone 28 survey method. Again, as with thedrone 28 method 29B, a handheld RFID reader 32 can be limited below fullEIRP due to the limited battery power in the handheld RFID reader 32. Ahandheld-based wireless RFID tag 22 is considered as semi-continuousmonitoring, with the frequency of monitoring set by the time intervalbetween handheld-based surveys.

A permanent fixed RFID reader or readers 33 can also be used to obtainwireless RFID tag 22 information, as described previously for the drone28 method 29B. Distance d4 between fixed RFID readers 33 is establishedbased on the reading range of the fixed RFID readers 33. Unlike portableRFID readers 29 and 32, which may have limited power, a fixed RFIDreader 33 can be powered locally from structure power, or from a batterypack that is recharged continuously with outside solar cells or othersource; therefore, the full EIRP is available, which allows for themaximum possible passive wireless RFID tags 22 reading range and acontinuous monitoring of data within the EIFS installation. The quantityof fixed RFID readers 33 needed to provide full reading coverage isdependent on the practical RFID reading range, the dimensions of thestructure with the EIFS installation, the available reading angles, andwhether any obstacles are present such as trees and other buildings.

Data can be uploaded directly to a cloud-based application 34 by thedrone 28, handheld reader 32, and fixed reader 22 using an onboard 4G or5G wireless cell connection, or the data can be relayed to another pointwhere it may be uploaded to the cloud-based application 34. In manyembodiments, the cloud-based application 34 can perform analysis on thedata to generate trend charts and statistical process-control charts,and to perform predictive analytics using applied statistics andArtificial Intelligence (AI)-based machine-learning algorithms. The AIalgorithms can be used to predict whether an EIFS installation couldsoon suffer build-up of excessive moisture so that preventative measurescan be timely taken before damage to the underlying structure occurs.The cloud-based application 34 can also augment the database withweather conditions encountered by each EIFS installation in order tohelp correlate the data obtained from the wireless RFID sensors withactual weather conditions encountered so that prediction capabilitiesare enhanced. The information from the cloud-application 34 can beavailable through a wireless application running on a smart phone 35 orthrough another remote computing device such as a tablet or computer.Furthermore, the cloud-based application 34 uses aggregate data from allEIFS installations uploading data in order to improve theleak-prediction capabilities of the AI-based algorithms.

FIG. 5A also depicts an embodiment for a method that can be used toperform a topographical mapping of an EIFS installation. Handheld RFIDreader 32 is equipped with a metalized directional-reading shield 32A tolimit the off-axis detection of wireless RFID tags 22.

When handheld RFID reader 32 detects a wireless RFID tag 22 immediatelyunder improved moisture-sensing insulating panel 1, or even within afully-clad EIFS installation, differential GPS device 31 records thelocation with high precision. This precision is typically within 25 cmhorizontally and 50 cm vertically using an internal antenna. An exampleof a surveyor-quality differential GPS GNSS handheld device that can beused is the Trimble Geo 7X Handheld (seehttps://geospatial.trimble.com/products-and-solutions/geo-7x) with anexternal fixed antenna reference. The unique digital ID, temperature,and capacitance readings from wireless RFID tag 22 as captured by RFIDreader 32, and precise location information from differential GPS device31, including photos or video records, can then be either stored in thememory of differential GPS device 31, or the data can be relayed to alocal computer-storage device, or the data can be uploaded to the cloudapplication 34. When all wireless RFID tag 22 within the EIFSinstallation have been located, read, and mapped (tag's unique digitalID associated with precision differential GPS location), thetopographical mapping of the EIFS installation will have been completed.This topographical mapping operation may only need to be performed onceimmediately after installation of the EIFS. The data from each wirelessRFID tag 22 allows the initial improved moisture-sensing insulationpanel 1/1A readings of the EIFS installation to be normalized byreferencing all future readings to this baseline (also referred to as acalibration tare). Any future improved moisture-sensing insulation panel1/1A readings that depart from the baseline will be obvious when trackedover time. An initial-installation verification can then be performed byensuring that no improved moisture-sensing insulation panels 1/1A departstatistically from the initial baseline. Any wireless RFID tags 22readings with departures from the baseline that are statisticallysignificant, are flagged as “Out-of-Family” (OOF) and warrant furtherinvestigation. OOF readings upon initial-installation verification canbe caused by improperly installed insulation panels from either too muchor too little basecoat 5 used to bond the improved moisture-sensinginsulation panels 1/1A to the barrier membrane 4.

The handheld topographical mapping of an EIFS installation can be usedfor smaller structures of <10 kSQF. As an example, assuming improvedmoisture-sensing insulation panels 1/1A of 2×4 feet (or 8-SQF each), 10kSQF implies around 1000 moisture-sensing insulation panels 1/1A panels,assuming that 25% of the surface area would be doors, windows, and otheropenings in the building structure. Therefore, it may be more-effectiveto perform the installation verification jointly with the installationprocess, or an installation verification immediately after each sectionof EIFS has been completed. It is also be possible to mount the RFIDreader 32 with directional reading shield 32A, differential GPS device31, and cameras or video-recording devices on a vehicle and drive slowlyaround the perimeter of a building structure. However, this methodologywould only be effective for structures that are no more than two storiesin height because of the range limitations of the RFID readers. Thedirectional nature of the initial topographical mapping survey requiresthat each wireless RFID tag 22 location be precisely known. Fortopographical mapping surveys by vehicle, it may be possible to use thephotographic or video-recording data to rebuild/map the location of eachwireless RFID tag 22 visually, but again the directional reading shield32A would be required to ensure that only one tag is being read at atime. As a result, the practicality of vehicle-based topographicalmapping may be limited.

In many embodiments, it is also possible to perform the topographicalmapping with a drone 28 using the RFID reader 29 and high-definitioncamera or video-recording device 30, along with the plurality of barcodes 27 stamped or printed onto the distal side of improvedmoisture-sensing insulation panels 1/1A. Because each bar code 27encodes the unique digital ID of the wireless RFID chip 22 containedwithin the improved moisture-sensing insulation panels 1/1A, thedrone-based observation is able to relate its data from each wirelessRFID tag 22 reading and correlate this data with the unique digital IDto the bar code 27. This can be accomplished by reading dozens or evenhundreds of wireless RFID tags 22 simultaneously within the field ofview of the high-definition camera or video-recording device 30. In somecases, it is possible to use the photographic or video-recording data torebuild/map the location of each wireless RFID tag 22 visually withinthe cloud application 34 without the need for a differential GPS 31device. The unique digital ID, temperature, and capacitance readingsfrom wireless RFID tag 22, as captured by RFID reader 32, and preciselocation information from photos or video records, can be relayed to alocal computer-storage device, or the data can be uploaded to the cloudapplication 34. When all wireless RFID tag 22 within the EIFSinstallation have been located, read, and mapped (tag's unique digitalID associated with precision differential GPS location), thetopographical mapping of the EIFS installation will have been completed.

Because topographical mapping by drone 28 relies on being able to imagethe plurality of bar codes 27 stamped or printed onto the distal side ofimproved moisture-sensing insulation panels 1/1A, it is necessary toperform the installation verification while the EIFS installationprocess is occurring. In this scenario, drone 28 with RFID reader 29 andhigh-definition camera or video-recording device 30, periodically sweepby the installation contractors as they are placing improvedmoisture-sensing insulation panels 1/1A in order to obtain wireless RFIDtag 22 readings while the plurality of bar codes 27 are visible, priorto the application of the strengthening mesh 8, basecoat 9, andfinishing coat 10. Finally, it is possible to print or apply the barcode 27 with a material such as conductive ink or polymers that have adifferent infrared signature from the base material of improvedmoisture-sensing insulation panels 1/1A, and/or the bar code 27 can beprinted onto raised or recessed areas that have a physical patternidentical with the bar code 27 pattern. In this case, it is possible toobtain the infrared image of the plurality of bar codes 27 throughstrengthening mesh 8, basecoat 9 and finishing coat 10. The followingrestrictions would apply for the infrared method described here: (1) Thehigh definition camera or video recording device 30 used for drone 28with RFID reader 29 must have infrared wavelength capability; (2) Themetalized bar code 27 placed on the distal side of improvedmoisture-sensing insulation panels 1/1A, have to be made as large aspossible to improve its infrared detectability; and (3) The metalizedbar code 27 placed on the distal side of improved moisture-sensinginsulation panels 1/1A have to be placed so as not to interfere with theantenna of wireless RFID tags 22 while the tags are being read.

Finally, some observations and notes must be made for the number ofimproved moisture-sensing insulation panels 1/1A required for an EIFSinstallation. Assuming 8-SQF per moisture-sensing insulation panels 1/1Aand 25% of a structure's vertical wall area is devoted to doors,windows, and other openings, as well as one wireless RFID tag 22 perimproved moisture-sensing insulation panels 1/1A, the number of wirelessRFID tags 22 required for a large EIFS installation may become excessive(e.g., approximately 10,000 tags for a 100 kSQF structure). In view ofthis, the following can be considered to mitigate this situation:

-   -   The size of the improved moisture-sensing insulation panels 1/1A        can be increased (this is especially true for prefabricated EIFS        panels) to also increase the coverage area of each panel; and/or    -   Improved moisture-sensing insulation panels 1/1A can be placed        in lower densities on center sections of wall (i.e., only every        other panel would be an improved moisture-sensing insulation        panels 1/1A and arranged in a checkerboard pattern) and only        concentrated in higher densities along known trouble areas such        as rooflines, windows, and other joints; and/or    -   State-of-the art UHF Gen-2 RFID readers can simultaneously read        nearly 1000 tags per second, which implies a drone 28 survey may        read as much as 10 kSQF area of installed EIFS paneling per        second. This may be limited in practice due to the building        geometry and readings angles coupled with the maximum reading        range as dictated by the RFID reader 29 EIRP available from the        drone 28 battery pack. Notably, a vehicle-borne survey would not        have the same power restrictions as the drone 28, so full EIRP        might be available and with it a maximum RFID reading range.        Therefore, it does not appear that the ability to obtain RFID        readings from an EIFS-clad structure is a limiting factor for        maximum wireless RFID tag 22 count.

Referring to the method flowchart of FIG. 6A, theinstallation-topography-mapping method consists of three basicfunctions/steps: (1) Readout data all RFID sensor tags; (2) Associatethe location of each RFID sensor tag with the physical location of thattag within the installation; and (3) Normalize the dry readings of allthe RFID sensor tags by using a calibration tare. Theinstallation-topography-mapping method is necessary to identify thephysical location of every RFID sensor tag within the EIFS installationand establish the dry baseline reading of the system. Theinstallation-topography-mapping process begins 101 after the “smart”EIFS with intrinsic moisture-sensing capability has been installed on astructure. The following algorithm is performed each time an RFID datareadout 102 is made:

-   -   IF the associated panel or membrane transponder (TID) barcode is        visible 104,    -   THEN (YES) associate the visible TID barcode 27 marking and with        the actual RFID data readout TID;    -   ELSE (NO) 103 use an alternate tag location method.

The alternate tag location method 103 may be using a very low RFIDreader; e.g., Effective Isotropic Radiated Power (ERIP) or ametalized-directional-reading shield; so that only the closest tag maybe read:

-   -   IF differential GPS is available 105,    -   THEN (YES) read the differential GPS location coordinate 107 and        write the differential GPS location coordinates 108 to the        non-volatile memory of the RFID tag:    -   ELSE (NO), write the visual or directional coordinates 106 to        the non-volatile memory of the RFID tag.

Optionally, even when differential GPS location coordinates 108 areavailable, the visual or directional coordinates 106 can also be writtento the non-volatile memory of the RFID tag. The visual or directionalcoordinates 103 can consist of locating the position of an RFID tagwithin the installation using a camera or laser rangefinder to determinethe distance and angular bearing from pre-surveyed physical datumsand/or using a camera to determine the location within a pre-plottedphysical grid marked upon the installation. The RFID tag moisture andtemperature reading 110 is made after the transponder ID (TID) and taglocation have been established.

As the RFID readings continue to be taken, the data for each RFID tag ischecked 111 for an Out-of-Family (OOF) reading when compared to all theother RFID tags read.

-   -   IF (YES) tag reading is OOF,    -   THEN begin a diagnostic routine 112 to determine the problem.    -   IF the reading anomaly 113 has been resolved (or addressed),    -   THEN (YES) send all the tag information 114 to the cloud        application database;    -   ELSE (NO) continue diagnostics 112 routines.    -   IF all tags in an installation have been read and location        mapped 116,    -   THEN (YES) the topographical mapping is complete 118;    -   ELSE (NO) continue 117 to read 102 more tags.

The installation-verification method depicted in the flowchart of FIG.6B consists of two basic functions/steps: (1) Readout test data all RFIDsensor tags with water placed on installed panels; and (2) Determinewhether any RFID sensor tag readings are OOF. Theinstallation-verification method is used to determine whether aninstalled EIFS is performing adequately under water-loading and/orwetted test conditions prior to being placed in service.

The installation verification process begins 200 after the EIFS withintrinsic moisture-sensing capability has been installed on a structureand only after the installation topography mapping method of FIG. 6Ahave been completed. The verification begins 201 by wetting the membraneor panels on all or part of an installation 202. This may require thespraying an air barrier or EIFS surface with water. After wetting, theRFID data readouts 203 are made and compared to the baseline readings118C from the topological mapping 204:

-   -   IF an RFID sensor reading 205 is OOF,    -   THEN (YES) enter installation problem routines 206 to locate the        leak or moisture-infiltration point;    -   ELSE (NO) send the installation verification data 208 along with        the date and time to the cloud application 115 b; the        installation verification has passed and is completed 209.

For OOF readings, SPC and other statistical methods known in the art canbe used to help establish the control limits where readings that falloutside the control limits are deemed as OOF. The cloud-basedapplication can be used to calculate and establish the preliminarycontrol limits used for installation-verification checks. Additionally,after many installations have been made and verified, the control limitscan be adjusted based on expected normal sensor-tag-reading behaviorunder installation verification conditions for each type ofinstallation. As an example, the drainage plane of an EIFS installationcan be expected to allow moisture to enter under wetted conditions, butthe drainage plane will then dry out over time. Therefore,EIFS-panel-moisture readings can be dynamic in nature, with moisturereadings that fluctuate with time, and departures from the expecteddynamic behavior constitutes an OOF condition.

V. Alternative Embodiments and Other Variations

The various embodiments and variations thereof described herein,including the descriptions in any appended Claims and/or illustrated inthe accompanying Figures, are merely exemplary and are not meant tolimit the scope of the inventive disclosure. It should be appreciatedthat numerous variations of the invention have been contemplated aswould be obvious to one of ordinary skill in the art with the benefit ofthis disclosure.

Hence, those ordinarily skilled in the art will have no difficultydevising myriad obvious variations and improvements to the invention,all of which are intended to be encompassed within the scope of theDescription, Figures, and Claims herein.

What is claimed is:
 1. An improved moisture-sensing-insulation panel foruse in above-ground building structures, having a proximal side that isintended to be installed facing the interior of a building structure anda distal side that is intended to be installed facing away from theinterior of a building structure, comprising: a structural paneldisposed on said proximal side of said improvedmoisture-sensing-insulation panel; a waterproof and vapor-impermeablemoisture-barrier membrane, disposed on the distal side of saidstructural panel; an insulating panel affixed to the distal side of saidmoisture-barrier membrane having a plurality of vertical-drainagechannels disposed on the proximal side of said insulating panel andadjacent to said moisture-barrier membrane, forming a drainage plane; atleast one moisture-sensing channel extending between at least twoopposing edges of said insulating panel and exposed to saidmoisture-barrier membrane, said at least one moisture-sensing channelhaving a proximal surface and containing within it a moisture-sensingmembrane, wherein: said at least one moisture-sensing channel intersectsat least most of said-vertical drainage channels, said moisture-sensingmembrane is comprised of: a first conductive metalized coating, a secondconductive metalized coating with a thin polymer or fluoropolymermembrane, a wicking layer is disposed upon between said first and secondconductive metalized coatings, said wicking layer substantiallycomprised of hydrophilic material, and one or more moisture-sensingdevices disposed on the distal side of said at least onemoisture-sensing channel, in electrical communication with each of saidfirst and second conductive metalized coatings; wherein: saidmoisture-sensing membrane has a width that is less than the width ofsaid at least one moisture-sensing channel to create a gap that allowsfor moisture to drain and contact said wicking layer, and said first andsecond conductive metalized coatings are electrically isolated from eachother; and a strengthening layer disposed on the distal side of saidinsulating panel.
 2. The improved moisture-sensing-insulation panel ofclaim 1, wherein at least one of said one or more moisture-sensingdevices is comprised of: a semi-permeable membrane disposed over theproximal side of said moisture-sensing membrane, over the area wheresaid moisture-sensing device resides, wherein: said semi-permeablemembrane has a plurality of perforations of a size of less than 5microns in diameter, and said semi-permeable membrane helps facilitatethe detection of the buildup of basecoat materials that compromise theeffectiveness of the drainage plane and resists the ionic contaminationof said moisture-sensing device; mastic sealant applied to thelongitudinal edges of said moisture-sensing device to resist ioniccontamination; and a wireless RFID tag in electrical communication witheach of said first and second conductive metalized coatings disposed onthe distal side of said semi-permeable membrane.
 3. The improvedmoisture-sensing-insulation panel of claim 2, wherein at least one ofsaid one or more moisture-sensing devices is adapted to measure coplanarcapacitance across said sensing membrane.
 4. The improvedmoisture-sensing-insulation panel of claim 2, wherein at least one ofsaid one or more moisture-sensing devices' wireless RFID tag is furthercomprised of an internal test load adapted to facilitate self-testingand diagnostic checks of the moisture-detection device residing withinsaid at least one moisture-sensing channel.
 5. The improvedmoisture-sensing-insulation panel of claim 2, wherein at least one ofsaid one or more moisture-sensing devices is adapted to measure biplanarcapacitance across said sensing membrane.
 6. The improvedmoisture-sensing-insulation panel of claim 2, wherein at least one ofsaid one or more moisture-sensing devices is adapted to measureresistance across said sensing membrane.
 7. The improvedmoisture-sensing-insulation panel of claim 2, wherein any cavity betweensaid wireless RFID tag and the other layers of said moisture-sensingmembrane is filled with insulating material and/or an elastomericadhesive potting compound in order to minimize the trapping of moistureand further protect said wireless RFID tag.
 8. The improvedmoisture-sensing-insulation panel of claim 1, wherein there are two ofsaid at least one moisture-sensing channel, with the twomoisture-sensing channels arranged in an X-pattern, extending fromcorner to corner of said improved moisture-sensing insulating panel. 9.The improved moisture-sensing-insulation panel of claim 1, wherein thereare a plurality of said at least one moisture-sensing channel, with themoisture-sensing channels densely arranged in a crossing patterns suchthat the moisture-sensing plane extends over the entire improvedmoisture-sensing insulating panel.
 10. The improvedmoisture-sensing-insulation panel of claim 1, wherein there is one ofsaid at least one moisture-sensing channel, with the moisture-sensingchannel arranged in a diagonal pattern, extending from one lower cornerto the opposite upper corner of said improved moisture-sensing panel.11. The improved moisture-sensing-insulation panel of claim 1, whereinsaid at least one moisture-sensing channel is arranged in a horizontalpattern, extending from one vertical edge to the opposite vertical edgeof said improved moisture-sensing panel.
 12. The improvedmoisture-sensing-insulation panel of claim 11, wherein a plurality ofsmall vertical channels are cut into the surface of said insulatingpanel in order to augment the augment the ability of said at least onemoisture-sensing channel to detect moisture.
 13. The improvedmoisture-sensing-insulation panel of claim 1, further comprising aplurality of bar-code patterns are ink-stamped or printed onto thedistal side of said improved moisture-sensing insulating panel, whereinsaid bar codes are encoded with the unique digital ID of the wirelessRFID tags of said installed wireless moisture-sensing devices that areco-located with said bar codes.
 14. The improvedmoisture-sensing-insulation panel of claim 1, further comprising aplurality of stenciled or printed “keep-away” areas disposed on thedistal surface of said insulating panel, wherein said plurality ofstenciled or printed “keep-away” areas are spatially aligned with saidat least one moisture-sensing channel and any moisture-sensing devicesdisposed therein such that persons installing said improvedmoisture-sensing insulation panel on a structure are provided visualindications of the locations of said plurality of moisture-sensingchannels and devices to avoid damaging any moisture-sensing devices. 15.A method to detect and process moisture-detection signals within abuilding structure, said building structure comprising at least oneimproved moisture-sensing insulation panels according to claim 1, themethod comprising the steps of: installing a building structure thatcomprises at least one improved moisture-sensing insulation panelaccording to claim 1; using an RFID reader, mapping the locations ofeach moisture-sensing device contained in said at least one improvedmoisture-sensing insulation panel; wirelessly transferring RFID readerdata to and from each moisture-sensing device contained in said at leastone improved moisture-sensing insulation panel; remotely collecting andstoring baseline data from said moisture-sensing devices contained insaid at least one improved moisture-sensing insulation panel; using anRFID reader, detecting moisture infiltration into said buildingstructure by reading the RFID tags for said moisture-sensing devicescontained in said at least one improved moisture-sensing insulationpanel; using an RFID reader, determining the location of the moistureinfiltration into said roofing structure by reading data from the RFIDtags for said moisture-sensing elements contained in said at least oneimproved moisture-sensing membrane; wirelessly transferring RFID readerdata to and from each moisture-sensing element contained in said atleast one improved moisture-sensing membrane; and remotely collectingand storing data from said moisture-sensing elements contained in saidat least one improved moisture-sensing membrane.
 16. The method of claim15, wherein the mapping step uses a GPS device in conjunction with saidRFID reader to map the locations of each moisture-sensing devicecontained in said at least one improved moisture-sensing insulationpanel.
 17. The method of claim 15, further comprising the steps of:using statistical methods to determine when moisture readings becomeout-of-family (OOF); using predictive analytics for at least oneimproved moisture-sensing membrane for said building structure; andusing encryption to protect both said transferred and stored datagathered from the at least one improved moisture-sensing insulationpanel of said building structure.
 18. The method of claim 15, furthercomprising the step of establishing a “keep-away” zone or visual markerson the surface of said at least one improved moisture-sensing membranein order to prevent damage said each moisture-sensing elements containedin said at least one improved moisture-sensing membrane during theinstallation of said roofing structure.
 19. The method of claim 15,wherein said RFID-tag readings are accomplished by one or more of thefollowing means: using a remotely-controlled or autonomous flying dronethat can fly within the RFID tags' range to make readings; and/or usinga mounted RFID reader with a directional reading shield, differentialGPS device, and high-definition cameras or video-recording devices on avehicle and driving slowly around the perimeter of said buildingstructure to make readings.
 20. The method of claim 15, wherein saidmoisture-sensing devices contained in said at least one improvedmoisture-sensing installation panel use electrical impedance within asensor-detection element or elements to sense the presence of moistureby measuring one or more of the following: biplanar capacitance;electrical resistance; both biplanar capacitance and electricalresistance; and/or changes in the antenna RLC impedance of theRFID-enabled sensor itself.